ELECTRIC POWER DESIGN FOR INDUSTRY

LECTURE 1. ELECTRICAL INSTALLATION

DESIGN CONSIDERATION

Safety of Life
shall

conform to relevant codes and standards provide adequate working space and safe clearances permit maintenance of equipment and circuits provide fully rated and protected equipment provide operations and maintenance instructions install emergency lighting for the safety and safe exit

DESIGN CONSIDERATION

Reliability of Utility Power Supply

power

supply at transmission voltage such as 120 kV or 230 kV is recommended

Reliability of Plant Distribution System

use

a minimum of two circuits or feeds, each from a different bus, to major and critical load centers system neutral grounding reduces transient overvoltage on single line-to ground faults

DESIGN CONSIDERATION

Simplicity of Operation and Maintenance

the majority of the faults in industrial systems are caused by insulation failure and sometimes by inadvertent or accidental contact design of an industrial power distribution system shall be simple, utilizing radial feeds

Voltage Regulation and Flicker Cost (Last Priority)

Safety, reliability, voltage regulation, maintenance, and provision for future expansion shall be given priority

METHODOLOGY
Listing of power demands Service connection:

MV

level LV level

Electrical Distribution architecture

i.e.

earthing, placing of equipments, etc

Protection against electric shocks Circuits and switchgear

METHODOLOGY
Protection against overvoltages Energy efficiency in electrial distribution Reactive energy Harmonics Particular supply sources and loads EMC (electromagnetic compatibility) Guidelines

POWER DEMAND

In industrial plant, electrical loads mostly consist of:

(AC induction, DC using inverter) Lighting
Motor

MOTORS LOAD
The nominal power in kW (Pn) of a motor indicates its rated equivalent mechanical power output. The apparent power in kVA (Pa) supplied to the motor is a function of the output, the motor efficiency and the power factor. power factor. Pn Pa cos

LIGHTING

The power Pn (watts) indicated on the tube of a fluorescent lamp does not include the power dissipated in the ballast.

Pballast Pn Pa cos

Standard pf for tubular fluorescent lamps (unless indicated): cos = 0.6 with no power factor (PF) correction cos = 0.86 with PF correction (single or twin tubes) cos = 0.96 for electronic ballast.

POWER LOADING
The installed power (kW) is the sum of the nominal powers of all power consuming devices in the Installation and it is not the power to be actually supplied in practice. The installed apparent power (kVA) is commonly assumed to be the arithmetical sum of the kVA of individual loads. The maximum estimated kVA to be supplied however is not equal to the total installed kVA

ESTIMATION OF KVA DEMAND

All individual loads are not necessarily operating at full rated nominal power nor necessarily at the same time Factors ku and ks allow the determination of the maximum power and apparent-power demands actually required to dimension the installation

FACTOR OF MAXIMUM UTILIZATION (KU)

In normal operating conditions the power consumption of a load is sometimes less than that indicated as its nominal power rating, a fairly common occurrence that justifies the application of an utilization factor (ku) in the estimation of realistic values. This factor must be applied to each individual load, with particular attention to electric motors, which are very rarely operated at full load (Ku=0,75).

FACTOR OF SIMULTANEITY (KS)

It is a matter of common experience that the simultaneous operation of all installed loads of a given installation never occurs in practice, i.e. there is always some degree of diversity and this fact is taken into account for estimating purposes by the use of a simultaneity factor (ks). The determination of these factors is the responsibility of the designer, since it requires a detailed knowledge of the installation and the conditions in which the individual circuits are to be exploited

EXAMPLE

DISTRIBUTION TYPES

VOLTAGE CONSIDERATIONS

The performance of the utilization equipment (motors, lighting, etc.) is guaranteed when the voltage and frequency applied to its terminals is within the limits specified in the standards For Indonesia:

Freq.:

50 Hz, Transmission (kV) : 20, 69, 150, 500 Distribution (kV) : 6, 20 Utilization (V) : 127/220, 220/380

TYPE OF TRANSFORMER
A Transformer is a device used to transfer electrical energy from
one circuit to another. With an alternating current, a transformer will either raise or lower the voltage as it makes the transfer.

Type of transformer normally depend on its cooling system.

Basicly, there are two main cooling system, which is dry and liquid.

DRY TYPE
the dry-type transformer has been popular since the 1930s atmospheric air is ultimately the coolant involved, but it is not always in direct contact with the transformer core and coils, and may not be relied upon as the dielectric. Some dry-type transformers are sealed within an inert gas atmosphere. Others are of the "cast coil" design in which the windings are fully encapsulated in a solid resin. Both of those designs were introduced about 40 years ago.

DRY TYPE
Dry-type transformers are available for voltages up to 34.5 kV (although the most common upper limit is 15) and kVA ratings up through 10,000 (with 5000 as the usual limit) The insulation system most common in a liquid-filled transformer is cellulose-based-paper covering on the conductors; pressboard spacers and supports. The materials are inexpensive, easy to work with, and when submerged in a dielectric fluid they offer a long and reliable service life (provided the fluid remains uncontaminated).

LIQUID TRAFO
Liquid trafo nowadays using oil as their element. In fact, with oil as their element, liquid trafo was the common

choosen for every decision, rather than dry type since

their cost was cheaper

OIL TRANSFORMER
Transformer oil, or insulating oil, is usually a highlyrefined mineral oil that is stable at high temperatures and has excellent electrical insulating properties. It is used in oil-filled transformers, some types of high voltage capacitors, fluorescent lamp ballasts, and some types of high voltage switches and circuit breakers. Its functions are to insulate, suppress corona and arcing, and to serve as a coolant.

The oil helps cool the transformer. Because it also provides part of the electrical insulation between internal live parts, transformer oil must remain stable at high temperatures for an extended period. To improve cooling of large power transformers, the oil-filled tank may have external radiators through which the oil circulates by natural convection. Very large or high-power transformers (with capacities of millions of KVA) may also have cooling fans, oil pumps, and even oil-to-water heat exchangers.

Large, high voltage transformers undergo prolonged drying processes, using electrical self-heating, the application of a vacuum, or both to ensure that the transformer is completely free of water vapor before the cooling oil is introduced. This helps prevent corona formation and subsequent electrical breakdown under load.

Oil filled transformers with a conservator (an oil tank above the transformer) tend to be equipped with Buchholz relays. These are safety devices that detect the build up of gases (such as acetylene) inside the transformer (a side effect of corona or an electric arc in the windings) and switch off the transformer. Transformers without conservators are usually equipped with sudden pressure relays, which perform a similar function as the Buchholz relay.

In the 1970s, polychlorinated biphenyls (PCB)s were often used as a dielectric fluid since they are not flammable. They are toxic, and under incomplete combustion, can form highly toxic products such as furan. Starting in the early 1970s, concerns about the toxicity of PCBs have led to their banning in many countries.

Today, non-toxic, stable silicone-based or fluorinated hydrocarbons are used, where the added expense of a fireresistant liquid offsets additional building cost for a transformer vault. Combustion-resistant vegetable oil-based dielectric coolants and synthetic pentaerythritol tetra fatty acid (C7, C8) esters are also becoming increasingly common as alternatives to naphthenic mineral oil. Esters are non-toxic to aquatic life, readily biodegradable, and have a lower volatility and a higher flash points than mineral oil.

COMPARISON
Liquid Advantages: 1. Low first cost 2. Suited for use dirty and dusty areas and in weather conditions 3. Lower sound levels Disadvantages: 1. The use is confined for outdoor installations 2. Unsuitable where fire is hazard and when vaults be provided 3. Heavy

DRY TRANSFORMER
Advantages: 1. Low first cost 2. Reliable when installed in proper locations and atmosphere 3. Leigh weight and can be installed anywhere 4. Fire or toxic fumes are not hazard with this type of transformer 5. Do not require vaults or special venting Disadvantages: 1. BIL is about half of liquid or gas filled unit 2. Cost is 20-25% higher than than oil-filled transformer 3. Technical and economical consideration dictate their selection

GAS TRANSFORMER
Advantages: 1. Suited for situation where cannot tolerate

CHOOSING TRANSFORMER
The possibility of improving the power factor of the installation Anticipated extensions to the installation Installation constraints (e.g. temperature) Standard transformer ratings

BIBLIOGRAPHY
Khan, Shoaib, 2008, Industrial Power Systems, CRC Press Taylor & Francis Group. Schneider Electric, 2008, Electrical Installation Guide, Schneider Electric Lazar, Irwin, 1980, Electrical Systems Analysis and Design for Industrial Plants, McGraw-Hill Book Company

ali@te.ugm.ac.id